Methods of creating composite parts with fibers in a desired orientation

ABSTRACT

Methods comprise generating an electric field; encompassing fibers within the electric to orient the fibers in a desired orientation relative to each other; and subsequent to the encompassing, fixing the fibers in the desired orientation within a matrix material to at least partially create a composite part.

FIELD

The present disclosure relates to creating composite parts.

BACKGROUND

Current techniques for creating composite parts with chopped fibercomposite pieces result in the random orientation of reinforcing fibersthroughout the composite parts. While such a random orientation ofreinforcing fibers may provide for uniform material properties acrosscomposite parts, it may be desirable for material properties to varyacross composite parts depending on the application of the compositeparts, the application or specific structure of a sub-region ofcomposite parts, etc. Current techniques do not permit for suchcustomized material properties at different locations across compositeparts.

SUMMARY

Methods comprise generating an electric field; encompassing fiberswithin the electric field to orient the fibers in a desired orientationrelative to each other; and subsequent to the moving, fixing the fibersin the desired orientation within a matrix material to at leastpartially create a composite part.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart schematically representing methods according tothe present disclosure.

FIG. 2 schematically illustrates an example of electrostaticallypolarizing fibers.

FIGS. 3A-3E schematically illustrate an example method according to thepresent disclosure.

FIGS. 4A-4D schematically illustrate an example method according to thepresent disclosure.

FIGS. 5A-5B schematically illustrate an example method according to thepresent disclosure.

FIGS. 6A-6C schematically illustrate an example method according to thepresent disclosure.

FIGS. 7A-7C schematically illustrate an example method according to thepresent disclosure.

FIG. 8 schematically illustrates an example method according to thepresent disclosure.

FIG. 9 schematically illustrates the result of an example methodaccording to the present disclosure.

FIG. 10 schematically illustrates the result of another example methodaccording to the present disclosure.

FIG. 11 schematically illustrates the results of additional examplemethods according to the present disclosure.

DESCRIPTION

FIG. 1 schematically provides a flowchart that represents illustrative,non-exclusive examples of methods 100 according to the presentdisclosure. In FIG. 1, some steps are illustrated in dashed boxesindicating that such steps may be optional or may correspond to anoptional version of a method according to the present disclosure. Thatsaid, not all methods according to the present disclosure are requiredto include the steps illustrated in solid boxes. The methods and stepsillustrated in FIG. 1 are not limiting and other methods and steps arewithin the scope of the present disclosure, including methods havinggreater than or fewer than the number of steps illustrated, asunderstood from the discussions herein.

Methods 100 according to the present disclosure may be described asmethods of creating composite parts, methods of at least partiallycreating composite parts, and/or methods of selectively aligning and/ormanipulating the orientation of fibers within a composite part as it isbeing created. In particular, methods 100 result in, or lead to, thefibers within a fiber-reinforced composite part having a desiredorientation, which orientation may be selected for various properties,as discussed herein. Because a desired orientation of the fibers may becontrolled, failure modes of the resulting composite part are morepredictable than under current chopped fiber composite moldingtechniques. Methods 100 may be used with current techniques fordirectional ply lay-ups, and to steer plies, tows, or tapes. Methods 100may be used to create a two-dimensional structure of chopped fiberplies, or fibers can be aligned at various angles between directionalplies, using tackifying stages, and/or creating a three-dimensionalinternal structure of a composite part. The methods 100 disclosed hereinmay be utilized in various aspects of composite manufacturing and theexamples disclosed herein are not limiting.

Methods 100 may find application in various industries including theaerospace, automotive, marine, construction, and space manufacturing andrepair industries, as well as any other industry where composite partsare manufactured and/or repaired. Methods 100 may be utilized to selector optimize such properties as mechanical properties, electricalproperties, magnetic properties, optical properties, and thermalproperties.

Specifically, as schematically represented in FIG. 1 and also withreference to the schematic examples of FIGS. 2-11 (discussed in greaterdetail below), methods 100 comprise generating (at 102) an electricfield 202, encompassing (at 103) fibers 201 within the electric field202 to orient the fibers 204 in a desired orientation relative to eachother, and subsequent to the encompassing 103, fixing (at 106) thefibers 204 in the desired orientation within a matrix material 206 to atleast partially create a composite part. In FIGS. 2-11, the fibers 204are very schematically represented as elongate cylinders solely for thesake of illustration, and the fibers 204 are not limited to beingcylindrical in shape.

As used herein, “fibers” 204, at least prior to performing the fixing106, encompasses any suitable fiber-like material used to construct afiber-reinforced composite structure according to methods 100, such as(but not limited to) one or more of dry fiber pieces (i.e., small (e.g.,greatest dimension typically in the range of 5-20 mm) dielectric fibersnot within a matrix material) or chopped fiber composite pieces. As usedherein, “chopped fiber composite pieces” refers to a class of compositematerial often used in a compression molding process, in which thecomposite material is composed of numerous small (e.g., greatestdimension typically in the range of 5-20 mm) pieces, chips, flakes,sheets, and/or other structures having fiber pieces embedded in adielectric matrix. Fiber pieces within chopped fiber composite piecesmay be carbon fibers, graphite fibers, boron fibers, aramid fibers,glass fibers, metal fibers, wood or other natural fibers, and/or othermaterials. The dielectric matrix of chopped fiber composite pieces maybe a thermoset plastic, a thermoplastic, a resin, an epoxy, and/or othermaterials and may be pre-cured, uncured, or partially cured prior to acomposite part formation process.

Fibers 204 typically have a length that is longer than a dimension thatis transverse or perpendicular to a length of the fibers 204 (e.g.,diameter, width, thickness, and/or height). As illustrative,non-exclusive examples, fibers 204 may have a length that is at leasttwo, at least three, at least five, or at least ten times greater than adiameter or a width of the fibers 204. Moreover, a fiber 204 may bedescribed as having a long, or longitudinal, axis that is aligned withits length. Accordingly, the desired orientation of the fibers 204 thatresults from the encompassing 103 may be characterized in terms of thelongitudinal axes of the fibers 204. For example, and as discussed ingreater detail herein, a desired orientation may have the longitudinalaxes of the fibers 204 generally aligned or parallel to each other.Other desired orientations also may result, as discussed herein.

The matrix material 206 may be any suitable material, such as selectedfor a specific application of the composite part, or portion thereof,being created according to a method 100. For example, the matrixmaterial 206 may be a thermoset plastic, a thermoplastic, a resin, anepoxy, and/or other material. When chopped fiber composite pieces areused as the fibers 204, the matrix material 206 utilized in the fixing106 may be the same as or different than the polymer of the choppedfiber composite pieces.

In some implementations of methods 100, the fibers 204 are dielectric.Accordingly, the fibers 204 may be well suited for beingelectrostatically polarized and thus being manipulated by the electricfield 202 during the encompassing 103.

In other implementations of methods 100, the fibers 204 are electricallyconductive. Such fibers may be selected for a particular application ofthe composite part, or portion thereof, being created according to amethod 100. For example, in some aerospace or other applications, it maybe desirable to utilize electrically conductive fibers to facilitate thedispersal of a lightning strike on a component. Additionally oralternatively, use of electrically conductive fibers in a composite partmay facilitate the absorption and/or reduction of reflection of radar,infrared, and/or sonar signals that are incident on the composite part.Other applications for electrically conductive fibers also exist.

In some implementations of methods 100, the fibers 204 themselvescomprise a composite material, such as with each of the fibers 204comprising reinforcing structure (e.g., carbon fibers, boron fibers,aramid fibers, glass fibers, wood or other natural fibers, and/or othermaterials) within a matrix (e.g., a polymer). Chopped fiber compositepieces, discussed above, are examples of such fibers 204. In some ofsuch examples, the matrix of the composite material is dielectric, andtherefore is well suited for being electrostatically polarized and thusbeing manipulated by the electric field 202 during the encompassing 103.In some examples, in which the fibers 204 comprise a composite material,the reinforcing structure additionally or alternatively is dielectric,and thus facilitates being electrostatically polarized and manipulatedby the electric field 202 during the encompassing 103. In otherexamples, the reinforcing structure is electrically conductive while thematrix is dielectric.

With continued reference to FIG. 1, some methods 100 further comprise,prior to the encompassing 103, electrostatically polarizing (at 108) thefibers 204. In such implementations of methods 100, theelectrostatically polarizing 108 facilitates the subsequent manipulationof the fibers 204 by the electric field 202. That is, byelectrostatically polarizing the fibers 204 prior to being encompassedby the electric field 202, the dipole moments of the fibers 204 areincreased, which results in enhanced alignment of the fibers 204 withthe electric field 202 during the encompassing 103. That said,electrostatically polarizing 108 is not required in all implementationsof methods 100, and simply encompassing the fibers 204 within theelectric field 202 may impart a polarization to the fibers 204,depending on the dielectric properties of the fibers 204.

With reference to FIGS. 1 and 2, in some implementations of methods 100,the electrostatically polarizing 108 comprises positioning (at 110) afirst structure 208 on a first side 210 of the fibers 204 and a secondstructure 212 on a second side 214 of the fibers 204 that is oppositethe first side 210, and applying (at 112) a voltage across the firststructure 208 and the second structure 212 sufficient toelectrostatically polarize the fibers 204. In FIG. 2, the fibers 204 areschematically represented as being supported by a support structure 216;however, the fibers 204 may be supported directly on whichever is lowerof the first and second structures 208, 212. Depending on the materialof the fibers 204 and the environment in which the electrostaticallypolarizing 108 is performed, the voltage applied may be in the tens ofthousands of volts. The first and second structures 208, 212 may takeany suitable form to adequately perform the electrostatically polarizing108, such as, but not limited to, conductive plates.

In FIGS. 3-6, the electric field 202 is schematically represented by aseries of dashed arrows. In some implementations of methods 100, theelectric field 202 is a pulsed electric field. In such examples, thepulsed electric field may assist in overcoming any friction betweenneighboring fibers 204, between the fibers 204 and the environment inwhich the fibers 204 are supported, and/or between the fibers 204 andany structure on which the fibers 204 are supported. In otherimplementations of methods 100, the electric field 202 is a staticelectric field.

Due to the polarization of the fibers 204, whether via the optional stepof electrostatically polarizing 108 or simply by being encompassedwithin the electric field 202, when the fibers 204 are within theelectric field 202, the longitudinal axes of the fibers 204 align withthe electric field 202, such as schematically represented in FIGS.3B-3D, 4B-4C, and 5A.

With continued reference to FIG. 1, in some implementations of methods100, the encompassing 103 comprises moving (104) the electric field 202relative to the fibers 204 so that the electric field 202 encompasses atleast some of the fibers 204 to orient the fibers 204 in the desiredorientation. Herein, “moving the electric field relative to the fibers”encompasses implementations (i) in which the fibers 204 physically aremoved in space while the electric field 202 is not moved, (ii) in whichthe electric field 202 is physically moved in space while the fibers 204are not moved (other than as a result of their interaction with electricfield 202 and gravity), and (iii) in which the fibers 204 and theelectric field 202 are moved in space relative to each other.

With continued reference to FIG. 1, as well as to the exampleimplementation of FIGS. 3-6, in some of such implementations of methods100, the moving 104 comprises producing (at 114) the electric field 202between two spaced-apart electrodes 218, and moving (at 116) one or bothof the electrodes 218 relative to the fibers 204. Such moving 116encompasses implementations (i) in which the fibers 204 physically aremoved in space while the electrodes 218 are not moved, (ii) in which theelectrodes 218 are physically moved in space while the fibers 204 arenot moved (other than as a result of their interaction with electricfield 202 and gravity), and (iii) in which the fibers 204 and theelectrodes 218 are moved in space relative to each other. In someimplementations of methods 100, the moving 104 further comprisesremoving (at 118) the fibers 204 from within the electric field 202,such that gravity causes the fibers 204 to lay-down on a surface in thedesired orientation.

FIGS. 3A-3E schematically illustrate an example implementation in whichthe moving 116 comprises moving the electrodes 218 in the same directionrelative to the fibers 204. More specifically, as seen in FIG. 3A, thefibers 204 are first supported on a support structure 216, with thefibers 204 being randomly oriented. In FIGS. 3B-3C, the fibers 204 arebeing brought into and partially encompassed by the electric field 202,which causes the longitudinal axes of the fibers 204 to align with theelectric field 202. Then, as seen in FIG. 3D-3E, as the fibers 204 areremoved from the electric field 202, the fibers 204 lay-down on thesupport structure 216 with their longitudinal axes generally aligned asa result of gravity and the effect of the edge of the electric field 202as the fibers 204 exit the electric field 202.

FIGS. 4A-4D schematically illustrate an example implementation in whichthe moving 116 comprises moving the electrodes 218 in differentdirections relative to the fibers 204, and more specifically in whichthe electrodes 218 are moved in opposite directions relative to thefibers 204. As seen in FIG. 4A, the fibers 204 are first supported on asupport structure 216, with the fibers 204 being randomly oriented. InFIG. 4B, the fibers 204 have been brought into and encompassed by theelectric field 202, which causes the longitudinal axes of the fibers 204to align with the electric field 202. Then, as seen in FIG. 4C-4D, asthe fibers 204 are removed from the electric field 202, the fibers 204lay-down on the support structure 216 with their longitudinal axesgenerally aligned as a result of gravity and the change in direction ofthe electric field 202 as the electrodes 218 move away from each otherand the fibers 204 exit the electric field 202.

In the schematic examples of FIGS. 3-4, the entirety of the fibers 204present are encompassed by the electric field 202, resulting in all ofthe fibers 204 being parallel or generally parallel to each other in thedesired orientation. However, also within the scope of methods 100 areimplementations in which, in the desired orientation, the fibers 204 arein a non-uniform orientation. For example, in some such implementations,in the non-uniform orientation, some of the fibers 204 are parallel orgenerally parallel to each other and are not parallel or generallyparallel to others of the fibers 204.

FIGS. 5A-5B schematically illustrate such an example implementation inwhich the moving 116 of the electrodes 218 relative to the fibers 204results in an overall non-uniform orientation of the fibers, but withsubsets of the fibers 204 being in uniform orientations. Morespecifically, as schematically represented in FIGS. 5A-5B, the electricfield 202 generated by the electrodes 218 does not fully encompass allof the fibers 204 supported by the support structure 216. As a result,when the electrodes 218 move relative to the fibers 204, only thosefibers 204 that are encompassed by the electric field 202 become alignedwith the electric field and lay-down on the support structure 216 withtheir longitudinal axes generally aligned as a result of gravity and theeffect of the edge of the electric field 202 as the fibers 204 exit theelectric field 202. Accordingly, such an implementation can create apath 220 of aligned fibers 204, which may be beneficial in variousapplications, such as when the fibers 204 include an electricallyconductive component to them. Additionally or alternatively, aligningthe fibers along a path may create desired physical propertiesassociated with the composite part being created according to a method100. Additionally or alternatively, aligning the fibers 204 along a pathmay facilitate subsequent work on the part, such as cutting, breaking,or drilling.

With reference to FIGS. 6A-6C and 7A-7C, in some implementations ofmethods 100, the encompassing 103 comprises moving a statically chargedstructure 228 relative to the fibers 204 to encompass the fibers in astatic electric field to orient the fibers 204 in the desiredorientation. In the example implementation of FIGS. 6A-6C, thestatically charged structure 228 is in the form of a cylindrical rodthat moves longitudinally relative to the fibers 204 to create a path220 of aligned fibers 204. In the example implementation of FIGS. 7A-7C,the statically charged structure 228 also is in the form of acylindrical rod; however, in the example of FIGS. 7A-7C, the cylindricalrod moves toward and then away from the fibers 204 to create a path 220of aligned fibers 204. In both examples, the statically chargedstructure 228 is smaller than a span of the fibers, such that with theillustrated example relative movements, only a subset of the fibers 204will be encompassed by the electric field. However, otherimplementations of methods 100 may include relative movement between thestatically charged structure 228 and the fibers 204, in which all of thefibers 204 ultimately are encompassed by the electric field 202.Moreover, the statically charged structure 228 may take any suitableshape and configuration to result in the desired orientation of thefibers 204.

In some implementations of methods 100, during the encompassing 103 (andduring the optional moving 104), the fibers 204 are within a gasenvironment, such as in air, with FIGS. 3-5 providing examples of suchimplementations. In some such examples, a gas may be flowed across thefibers 204 to aid in the laying down of the fibers 204 in the desiredorientation as they are removed from the electric field 202. In otherimplementations of methods 100, during the encompassing 103 (and duringthe optional moving 104), the fibers 204 are within a flowing slurry222. That is, the fibers 204 are within a flowing liquid, such as aresin (e.g., during an injection molding process). In some suchimplementations, the slurry 222 comprises a molten material, such asthat will become the matrix material 206 of the composite part beingformed. FIG. 6 schematically illustrates an example in which the fibers204 are within a flowing slurry 222. As seen in FIG. 6, the slurry 222flows through a conduit 224, with an electric field 202 (e.g., generatedbetween two electrodes 218) encompassing at least a portion of theconduit 224. Accordingly, as the slurry 222 passes through the electricfield 202, the fibers 204 within the slurry 222 will first align withinthe electric field 202 and then, as the fibers 204 exit the electricfield 202, the fibers 204 will align with the direction of flow of theslurry 222. Such implementations of methods 100 may be well suited forcreating elongate composite structures with fibers 204 aligned with thelongitudinal axes of the elongate composite structures and/or as part ofan injection molding process. Moreover, such implementations of methods100 may be used during a fiber-reinforced resin injection method, inwith the orientation of the fibers 204 are manipulated externally.

In some implementations of methods 100, in the desired orientation,voids 226 are present within regions of the fibers 204, or in otherwords, the fibers in the desired orientation are arranged in regionsthat define one or more voids 226. FIG. 11 schematically representsillustrative, non-exclusive examples of voids 226 within regions of thefibers 204. As used herein, a “void” is a region of the matrix material206 having a greatest linear dimension that is at least twice the length(or average length) of the fibers 204, in which the fibers 204 are notpresent. In FIG. 11, two generally circular voids 226 and one generallylinear void 226 are schematically represented, but voids 226 may takeany suitable size and shape depending on a particular application of thevoids 226. As illustrative, non-exclusive examples, voids 226 may becreated such that the composite part comprises one or more of a scoreline, a fracture point, or a drill hole location associated with a void226 and thus with the desired orientation. For example, by creatingvoids 226, subsequent work on the composite part (e.g., cutting,breaking, or drilling) may avoid cutting of reinforcing fibers and thusmay result in easier and cleaner working of the composite part.Additionally or alternatively, such subsequent working of the compositepart may avoid or at least reduce stress concentrations in the compositepart. Additionally or alternatively, in some implementations of methods100, the composite part comprises a radius associated with the desiredorientation. For example, a void 226 that defines a drill hole locationmay be described as being associated with a radius of the drill hole. Inother examples, the fibers 204 may be preferentially oriented togenerally conform to a rounded corner of a structure, for example.

In some implementations of methods 100, the desired orientation of thefibers 204 imparts uniform material properties to the composite part. Inother implementations of methods 100, the desired orientation of thefibers 204 imparts non-uniform material properties to the compositepart. Such material properties may comprise one or more of mechanicalproperties, electrical properties, magnetic properties, opticalproperties, and thermal properties, such as depending on the materialselected for the fibers 204 and the matrix material 206.

Turning back to FIG. 1, in some implementations of methods 100, thefixing 106 comprises applying (at 120) a tackifier to the fibers 204,with the tackifier comprising the matrix material 206. A tackifier maybe applied in any suitable manner, including spraying or dripping aliquid tackifier onto the fibers 204 to encompass the fibers 204 withinthe matrix material 206. Additionally or alternatively, in someimplementations of methods 100, the fixing 106 comprises applying (at122) a tape to the fibers 204, with the tape comprising the matrixmaterial 206. Additionally or alternatively, in some implementations ofmethods 100, the fixing 106 comprises compacting (at 124) the compositepart. Additionally or alternatively, in some implementations of methods100, the fixing 106 comprises at least partially curing (at 126) thecomposite part.

FIGS. 9-11 schematically illustrate non-exclusive examples of desiredorientations of fibers 204 following the fixing 106. In FIG. 9, all ofthe fibers 204 are aligned or generally aligned with each other. In FIG.10, the fibers 204 of a first subset of the fibers 204 are aligned orgenerally aligned with each other, and the fibers 204 of a second subsetof the fibers 204 are aligned or generally aligned with each other andare transverse to the first subset. In FIG. 11, as discussed above,three example voids 226 are present.

In some implementations of methods 100, the fixing 106 creates a ply ofcomposite material, that is, a sheet or film of composite material inwhich the length and width is significantly greater than the thicknessor depth of the composite material. With reference again to FIG. 1, somesuch implementations, methods 100 further comprise repeating (at 128) atleast the generating 102, the moving 104, and the fixing 106, andoptionally the electrostatically polarizing 108, to create one or moreadditional plies of composite material, and then stacking (at 130) theplies of composite material.

In some such implementations of methods 100, as indicated in FIG. 1, thestacking 130 comprises orienting (at 132) the fibers 204 of the one ormore additional plies of composite material transverse to the fibers 204of the first ply of composite material. For example, plies, as in theexample of FIG. 9, each may have aligned fibers 204, and the plies maybe stacked such that the fibers 204 are sequentially oriented at desiredangles relative to each other (e.g., in a 0°, 45°, 90°, and 135°pattern). Other patterns of relative angles may be selected forparticular applications and desired resulting properties of thecomposite part being created.

A resulting structure of stacked plies may be described as a lay-up ofcomposite plies, which then may be used in a downstream method ofcreating a greater composite part according to known techniques.

Additionally or alternatively, an implementation of a method 100 mayresult in a ply of composite material, in which the fibers 204 areoriented out-of-plane of the ply, that is, with the long axes of atleast a subset of the fibers 204 being transverse, or oblique, to theplane of the ply. When such a ply or plies are subsequently stacked withone or more additional plies, the out-of-place fibers 204 may reducedelamination, that is, may increase the cohesion between adjacent plies.

In some implementations of methods 100, the moving 104 is performedwhile the fibers 204 are within a viscous material of an at leastpartially assembled composite assembly, that is, with the matrixmaterial 206 being in a viscous state. For example, and as indicated inFIG. 1, some methods 100 further comprise curing (at 134) the at leastpartially assembled composite assembly, such that the moving 104 isperformed concurrently with the curing 134, and the viscous material isviscous as a result of the curing 134. For example, the moving 104 maybe performed while the at least partially assembled composite assemblyis being cured in an autoclave, during which time the matrix material206 is sufficiently viscous to permit the manipulation of theorientation of the fibers 204 within the matrix material 206 as a resultof the movement of the electric field 202.

Illustrative, non-exclusive examples of inventive subject matteraccording to the present disclosure are described in the followingenumerated paragraphs:

A. A method, comprising:

generating an electric field;

encompassing fibers within the electric field to orient the fibers in adesired orientation relative to each other; and

subsequent to the encompassing, fixing the fibers in the desiredorientation within a matrix material to at least partially create acomposite part.

A1. The method of paragraph A, wherein the fibers comprise chopped fibercomposite pieces.

A2. The method of any of paragraphs A-A1, wherein the fibers aredielectric.

A3. The method of any of paragraphs A-A2, wherein the fibers comprise acomposite material.

A4. The method of any of paragraphs A-A3, wherein each of the fiberscomprises reinforcing structure within a matrix.

A4.1. The method of paragraph A4, wherein the matrix is dielectric.

A4.2. The method of any of paragraphs A4-A4.1, wherein the reinforcingstructure is dielectric.

A4.3. The method of any of paragraphs A4-A4.1, wherein the reinforcingstructure is electrically conductive.

A5. The method of any of paragraphs A-A4.3, further comprising, prior tothe encompassing, electrostatically polarizing the fibers.

A5.1. The method of paragraph A5, wherein the electrostaticallypolarizing comprises:

positioning a first structure on a first side of the fibers and a secondstructure on a second side of the fibers that is opposite the firstside; and

applying a voltage across the first structure and the second structuresufficient to electrostatically polarize the fibers.

A6. The method of any of paragraphs A-A5.1, wherein the electric fieldis a pulsed electric field.

A7. The method of any of paragraphs A-A5.1, wherein the electric fieldis a static electric field.

A8. The method of any of paragraphs A-A7, wherein when the fibers arewithin the electric field, longitudinal axes of the fibers align withthe electric field.

A9. The method of any of paragraphs A-A8, wherein the encompassingcomprises moving the electric field relative to the fibers from aconfiguration in which none of the fibers are encompassed by theelectric field to a configuration in which the electric fieldencompasses at least some of the fibers to orient the fibers in thedesired orientation.

A9.1. The method of paragraph A9, wherein the moving the electric fieldrelative to the fibers comprises:

producing the electric field between two spaced-apart electrodes; and

moving one or both of the electrodes relative to the fibers.

A9.1.1. The method of paragraph A9.1, wherein the moving one or both ofthe electrodes comprises moving the electrodes in opposite directionsrelative to the fibers.

A9.1.2. The method of any of paragraphs A9.1-A9.1.1, wherein the movingone or both of the electrodes comprises moving the electrodes indifferent directions relative to the fibers.

A9.1.3. The method of any of paragraphs A9.1-A9.1.1, wherein the movingone or both of the electrodes comprises moving the electrodes in thesame direction relative to the fibers.

A9.2. The method of any of paragraphs A9-A9.1.3, wherein theencompassing further comprises removing the at least some of the fibersfrom the electric field, such that gravity causes the at least some ofthe fibers to lay-down on a surface in the desired orientation.

A10. The method of any of paragraphs A-A9.2, wherein in the desiredorientation, all of the fibers are parallel or generally parallel toeach other.

A11. The method of any of paragraphs A-A9.2, wherein in the desiredorientation, the fibers are in a non-uniform orientation.

A11.1. The method of paragraph A11, wherein in the non-uniformorientation, some of the fibers are parallel or generally parallel toeach other and are not parallel or generally parallel to others of thefibers.

A12. The method of any of paragraphs A-A11.1, wherein in the desiredorientation, voids are present within regions of the fibers.

A13. The method of any of paragraphs A-A12, wherein the desiredorientation imparts uniform material properties to the composite part.

A14. The method of any of paragraphs A-A12, wherein the desiredorientation imparts non-uniform material properties to the compositepart.

A15. The method of any of paragraphs A13-A14, wherein the materialproperties comprise one or more of mechanical properties, electricalproperties, magnetic properties, optical properties, and thermalproperties.

A16. The method of any of paragraphs A-A15, wherein the composite partcomprises one or more of a score line, a fracture point, a drill holelocation, or a radius associated with the desired orientation.

A17. The method of any of paragraphs A-A16, wherein during theencompassing, the fibers are within a slurry.

A18. The method of any of paragraphs A-A16, wherein during theencompassing, the fibers are within a gas environment.

A19. The method of any of paragraphs A-A18, wherein the fixing comprisesapplying a tackifier to the fibers, and wherein the tackifier comprisesthe matrix material.

A20. The method of any of paragraphs A-A19, wherein the fixing comprisesapplying a tape to the fibers, and wherein the tape comprises the matrixmaterial.

A21. The method of any of paragraphs A-A20, wherein the fixing comprisescompacting the composite part.

A22. The method of any of paragraphs A-A21, wherein the fixing comprisesat least partially curing the composite part.

A23. The method of any of paragraphs A-A22,

wherein the fixing creates a first ply of composite material; and

wherein the method further comprises:

-   -   repeating the generating, the encompassing, and the fixing with        respect to new fibers to create one or more additional plies of        composite material; and    -   stacking the first ply of composite material with the one or        more additional plies of composite material.

A23.1. The method of paragraph A23, wherein the stacking comprisesorienting the fibers of the one or more additional plies of compositematerial transverse to the fibers of the first ply of compositematerial.

A24. The method of any of paragraphs A-A22, wherein the encompassing isperformed while the fibers are within a viscous material of an at leastpartially assembled composite assembly, wherein the viscous materialcomprises the matrix material.

A24.1. The method of paragraph A24, further comprising curing the atleast partially assembled composite assembly, wherein the encompassingis performed concurrently with the curing, and wherein the viscousmaterial is viscous as a result of the curing.

A25. The composite part at least partially created according to themethod of any of paragraphs A-A24.1.

As used herein, the terms “adapted” and “configured” mean that theelement, component, or other subject matter is designed and/or intendedto perform a given function. Thus, the use of the terms “adapted” and“configured” should not be construed to mean that a given element,component, or other subject matter is simply “capable of” performing agiven function but that the element, component, and/or other subjectmatter is specifically selected, created, implemented, utilized,programmed, and/or designed for the purpose of performing the function.It is also within the scope of the present disclosure that elements,components, and/or other recited subject matter that is recited as beingadapted to perform a particular function may additionally oralternatively be described as being configured to perform that function,and vice versa. Similarly, subject matter that is recited as beingconfigured to perform a particular function may additionally oralternatively be described as being operative to perform that function.

As used herein, the term “and/or” placed between a first entity and asecond entity means one of (1) the first entity, (2) the second entity,and (3) the first entity and the second entity. Multiple entries listedwith “and/or” should be construed in the same manner, i.e., “one ormore” of the entities so conjoined. Other entities optionally may bepresent other than the entities specifically identified by the “and/or”clause, whether related or unrelated to those entities specificallyidentified. Thus, as a non-limiting example, a reference to “A and/orB,” when used in conjunction with open-ended language such as“comprising,” may refer, in one example, to A only (optionally includingentities other than B); in another example, to B only (optionallyincluding entities other than A); in yet another example, to both A andB (optionally including other entities). These entities may refer toelements, actions, structures, steps, operations, values, and the like.

The various disclosed elements of apparatuses and steps of methodsdisclosed herein are not required to all apparatuses and methodsaccording to the present disclosure, and the present disclosure includesall novel and non-obvious combinations and subcombinations of thevarious elements and steps disclosed herein. Moreover, one or more ofthe various elements and steps disclosed herein may define independentinventive subject matter that is separate and apart from the whole of adisclosed apparatus or method. Accordingly, such inventive subjectmatter is not required to be associated with the specific apparatusesand methods that are expressly disclosed herein, and such inventivesubject matter may find utility in apparatuses and/or methods that arenot expressly disclosed herein.

1. A method, comprising: generating an electric field; encompassingfibers within the electric field to orient the fibers in a desiredorientation relative to each other; and subsequent to the encompassing,fixing the fibers in the desired orientation within a matrix material toat least partially create a composite part.
 2. The method of claim 1,wherein the fibers comprise chopped fiber composite pieces.
 3. Themethod of claim 1, wherein the fibers are dielectric.
 4. The method ofclaim 1, wherein each of the fibers comprises a reinforcing structurewithin a matrix, and wherein the matrix is dielectric.
 5. The method ofclaim 4, wherein the reinforcing structure is electrically conductive.6. The method of any of claim 1, further comprising, prior to theencompassing, electrostatically polarizing the fibers.
 7. The method ofclaim 6, wherein the electrostatically polarizing comprises: positioninga first structure on a first side of the fibers and a second structureon a second side of the fibers that is opposite the first side; andapplying a voltage across the first structure and the second structuresufficient to electrostatically polarize the fibers.
 8. The method ofclaim 1, wherein the electric field is a pulsed electric field.
 9. Themethod of claim 1, wherein when the fibers are within the electricfield, longitudinal axes of the fibers align with the electric field.10. The method of claim 1, wherein the encompassing comprises moving theelectric field relative to the fibers from a configuration in which noneof the fibers are encompassed by the electric field to a configurationin which the electric field encompasses at least some of the fibers, toorient the fibers in the desired orientation.
 11. The method of claim10, wherein the moving the electric field relative to the fiberscomprises: producing the electric field between two spaced-apartelectrodes; and moving one or both of the electrodes relative to thefibers.
 12. The method of claim 11, wherein the moving one or both ofthe electrodes comprises moving the electrodes in opposite directionsrelative to the fibers.
 13. The method of claim 11, wherein the movingone or both of the electrodes comprises moving the electrodes in thesame direction relative to the fibers.
 14. The method of claim 10,wherein the encompassing further comprises removing the at least some ofthe fibers from within the electric field, such that gravity causes theat least some of the fibers to lay-down on a surface in the desiredorientation.
 15. The method of claim 1, wherein in the desiredorientation, all of the fibers are parallel or generally parallel toeach other.
 16. The method of claim 1, wherein in the desiredorientation, the fibers are in a non-uniform orientation.
 17. The methodof claim 16, wherein in the non-uniform orientation, some of the fibersare parallel to each other, and are not parallel or generally parallelto others of the fibers.
 18. The method of claim 1, wherein in thedesired orientation, voids are present within regions of the fibers. 19.The method of claim 1, wherein the desired orientation imparts uniformmaterial properties to the composite part.
 20. The method of claim 1,wherein the desired orientation imparts non-uniform material propertiesto the composite part.
 21. The method of claim 1, wherein the compositepart comprises one or more of a score line, a fracture point, a drillhole location, or a radius associated with the desired orientation. 22.The method of claim 1, wherein during the encompassing the electricfield relative to the fibers, the fibers are within a slurry.
 23. Themethod of claim 1, wherein during the encompassing the electric fieldrelative to the fibers, the fibers are within a gas environment.
 24. Themethod of claim 1, wherein the fixing comprises applying a tackifier tothe fibers, and wherein the tackifier comprises the matrix material. 25.The method of claim 1, wherein the fixing comprises applying a tape tothe fibers, and wherein the tape comprises the matrix material.
 26. Themethod of claim 1, wherein the fixing comprises compacting the compositepart.
 27. The method of claim 1, wherein the fixing comprises at leastpartially curing the composite part.
 28. The method of claim 1, whereinthe fixing creates a first ply of composite material; and wherein themethod further comprises: repeating the generating, the encompassing,and the fixing with respect to new fibers to create one or moreadditional plies of composite material; and stacking the first ply ofcomposite material with the one or more additional plies of compositematerial.
 29. The method of claim 1, wherein the encompassing theelectric field relative to the fibers is performed while the fibers arewithin a viscous material of an at least partially assembled compositeassembly, wherein the viscous material comprises the matrix material.30. The method of claim 29, further comprising curing the at leastpartially assembled composite assembly, wherein the moving the electricfield relative to the fibers is performed concurrently with the curing,and wherein the viscous material is viscous as a result of the curing.